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CENTAC C700

C700
BASIC FRAME DESCRIPTION

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CENTAC C700

Basic Frame Description

1 Introduction
The CENTAC C700 compressor is a reliable and efficient multistage centrifugal compressor that is designed
to provide oil-free compressed air or nitrogen.
CENTAC compressors are designed as fully packaged units including an air end, a driver, an IR developed
state-of-the-art control panel with microprocessor, an air cooling system and a self-contained lubrication
systems, all mounted on a common fabricated steel baseplate.
Some of the outstanding features and benefits are:

Standard features Benefits

Compact package on rigid baseplate No special foundation required
Mounted intercoolers and aftercooler Compact efficient design
Baseplate mounted control panel Prewired and factory tested
Fewest electrical hookups Minimal installation time and cost

2 CENTAC Principles of Operation

Air enters the compressor through the
machine mounted inlet control valve and (3) Intercooler
flows to the first stage where the
(2) Diffuser
impeller (1) imparts velocity to the air.
The air proceeds through the stationary (1) Impeller
diffuser section (2) where the kinetic
energy (velocity) is converted to static
energy (pressure). The built-in inter-
cooler (3) removes the heat of com-
pression and improves compressor’s ef-
ficiency. Air then passes through a
stainless steel moisture separator (4) in
a low velocity zone to remove con-
densate. Entrained moisture in the air is
reduced when the air is forced through
stainless steel moisture separators. This
sequence repeats in each succeeding (4) Moisture separator
stage until the compressor achieves the
desired operating pressure.
Fig. 1: CENTAC principles of operation

3 General Description
The compressor package contains:
• Two or three high efficiency compression stages, each consisting of an impeller mounted on its own
shaft, enclosed within a common cast iron casing.
• A flange or baseplate mounted electric motor coupled to the compressor through a coupling that
compensates for angular misalignments between shafts. The motor directly drives a bullgear that is
common to all stages.
• Rotors consisting of an integral pinion gear, driven at its optimum speed by the bullgear, and an impeller.
• One or two intercoolers and one aftercooler (except for high pressure units from 174 – 261 psi.
• A moisture separator and a moisture removal system to remove condensate (not applicable on nitrogen
units).

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CENTAC C700

4 Air End Gear casing

Stage head
The air end of CENTAC compressor consists of following
main components:
• Casing, including:
- gear casing
- gear casing cover
- stage heads
• Gearings Gear casing
cover
• Rotor assemblies
• Impeller
• Diffusers
• Bearings

Fig. 2: C700 Air End

4.1 Casing
The casing consists of two halves (gear casing and gear
Crossover
cover) that are bolt together to make-up the linebore. The
gear cover is located on the motor side, while the gear
casing is located on the compressor side. The vertical split
allows an easy insertion and removal of bearings and rotor
assemblies without disassembling the gear casing.
Stage heads are bolted to the gear casing and can be
easily removed for servicing or inspection. Inlet, discharge
and by-pass flanges are integral with the inlet and
discharge head covers, providing maximum rigidity and
minimum stress on running parts. Inlet and discharge water
connection for each cooler are integral with the cooler
covers. Fig. 3: Hot discharge air end
nd
On hot discharge units a crossover connects the 2 stage discharge to the inlet of the 3rd stage head.

4.2 Gearings
Built-in precision helical gearings (AGMA
12) consist of a bull-gear directly coupled
to the driver and individual pinion gear for
each stage, sized so that each impeller
runs at its optimum speed.

4.3 Rotor Assemblies

Each rotor assembly consists of an ef- Fig. 5: Polygon profile shaft
Fig. 4: Bull-gear & impellers
ficient and high quality stainless steel (15-
5 PH) impeller and a removable thrust
collar mounted on a helical geared pinion Pinion
shaft. The thrust collar allows dissipation
of aerodynamic thrust loads generated
during operations and prevents the
transmission of the loads to the main gear
train and maximizes gear life.
The impeller and thrust collar are each Thrust collar
secured to the shaft by a polygon spline,
which tightens under thermal loadings and
Fig. 6: Rotor assembly

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CENTAC C700

eliminates the need for stress-producing

keyways, and retained with a bolt. The
new CENTAC design has the male half on
the impeller and the female half in the
pinion.
All rotating parts are dinamically balanced
as a complete assembly. The correct
mechanical behaviour of the rotor assem-
blies is continuously controlled by radial Fig. 8: Vibration probe
vibration probes located next to the jour-
nal bearing assembly and connected by a Fig. 7: Impeller
cable to a vibration transmitter mounted inside the CMC control panel.

4.4 Impellers
Designed to resist corrosion, the impellers are of high quality stainless steel (15-5 PH). Impellers are 5-axis
machined and are designed with backward leaning vanes for peak performance and stable operating range.

4.5 Diffusers
The diffuser converts kinetic energy to pressure energy and is located
between each impeller and cooler. Diffusion and pressure recovery are
accomplished in the first row of vanes in the diffuser. A second row of
vanes is located in the axial passageway leading to the cooler inlet in
order to remove residual swirling of the air for highest overall stage
efficiency. Diffusers are machined single-piece aluminium diffusers
with Nituff coating on 2nd and 3rd stage for high protection against
corrosion.

Fig. 9: Diffuser
4.6 Bearings Pocket
Each pinion is supported by a fixed pad
journal bearing on impeller side and by a
fixed pad journal bearing with integral
thrust bearing (pocket type) and a
reverse thrust bearing (tapered land type
- for operations in unloaded conditions)
on collar side. The journal and thrust
bearings are hydrodynamic and have a
long lifecycle.
The bullgear also uses hydrodynamic
bearings for journal and thrust loads.
Fig. 10: Fixed pad journal bearing Fig. 11: Thrust bearing
All bearings are designed to maximize
load carrying capacities and babbitt lined
to minimize power loss.

4.7 Seals
There are two types of seals used on CENTAC compressors:
• double lip seals on the bullgear shaft
• a cartridge seal with fully floating non-contact carbon rings on the rotor assembly

The cartridge seal is mounted in the plain bearing housing behind each impeller and consists of three fully
floating non-contact carbon rings. One ring is used as an air seal and the remaining two as oil seals. Process

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CENTAC C700

air is prevented from being leaked into the compressor Seal air
casing by the first carbon ring. Seal air is injected injection
between the two oil seal rings at 9 psi to prevent oil
entering the air stream and to assure that the Pinion side
compressed air is oil-free and environmentally clean (oil)
for applications such as food, beverage, electronics
and pharmaceuticals. A vent to atmosphere is provided
between the air and oil seals.

5 Air System Air vent Floating

carbon rings
The air system of CENTAC compressor includes
following main components:
• inlet air filter Impeller side
(process air) Floating
• inlet throttle valve
carbon ring
• air coolers
Fig. 12: Cartridge seal
• moisture separators
• condensate traps
• by-pass valve
• by-pass silencer
• discharge check valve
• instrumentation

5.1 Inlet air filter

The inlet air filter is a 2-stage dry type filter with
fixed louvre and replaceable elements, with an
efficiency >98% at 2 micron. This filter uses a
primary and secondary element to filter the
incoming air stream. This allows for the removal
and cleaning of the first stage filter without
shutting down the compressor. The filter
includes also an integrated bypass silencer for
the blow-off air. The filter is designed for indoor
or outdoor under roof installation and covers a
variety of flow ranges. The inlet air filter/bypass
silencer is shipped loose.

Fig. 13: Inlet air filter with integrated bypass silencer

5.2 Inlet throttle valve
The inlet throttle valve modulates the air intake to the compressor
to maintain constant discharge pressure under different air
requirement in the down stream system. It is machine mounted,
complete with electropneumatic transducer, pressure regulator,
pressure gauge, pneumatic actuator and positioner.

5.3 Air coolers

CENTAC C700 compressor has one or two intercoolers
(depending on number of stages) and one aftercooler (except for
high pressure units from 174 – 261 psi). Fig. 14: Inlet throttle valve
The air coolers utilize cartridge coolers mounted internal to the
compressor casing. The passage of the heat from the air to water

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CENTAC C700

is assisted by the internal fins in the air passages,

which greatly increase the effective heat transfer area
on the air side. The air side fins are lead coated to
resist corrosion. The CENTAC air-in-tube/water-in-
shell design with counter flow arrangement provides
also following important benefits:
• best heat transfer and lowest pressure drop
• air noise damping
• less performance deterioration due to fouling Air flow to the impeller
• low water flow requirement and less cooler main- Hot compressed air from the diffuser
tenance Cooled compressed air
• back-flushing capability during operation Fig. 15: Intercooler cartridge

5.4 Cooling Water Manifold

C700 is provided with a flanged common
cooling water manifold that distributes cooling
water to each stage and requires a single-
point inlet/outlet water connection. Fig. 16: Finned air tube

5.5 Moisture Separators

Fig. 17: Cooling water manifold

The moisture separator is of stainless steel mesh screen type construction.

The thickness of the separator is designed to separate the maximum
amount of moisture at a minimal pressure drop. The separators are located
at points in the compressor where air velocities are relatively low permitting
effective moisture separation.

5.6 Condensate traps

Fig. 18: Moisture separator

These traps are mounted and piped below each

moisture separator for moisture removal. Standard
traps (direct ball float type) are furnished complete
with a by-pass valve to control the operation of the
trap itself.

5.6 By-pass valve

The by-pass valve is machine mounted, complete
with electropneumatic transducer, pressure
regulator, pressure gauge, pneumatic actuator and Fig. 19: Condensate trap
positioner. It unloads to the atmosphere the excess
of air when the system’s requirements falls below
the minimum throttle capacity handled by the inlet
valve.

5.7 Discharge check valve

The check valve, machine mounted, is a simple non return valve
provided to close the outlet and prevent back-flow of the air from
the system to the compressor during off-load periods.
Fig. 20: By-pass valve and check valve

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CENTAC C700

6 Lubrication System
The lubrication system of the compressor is completely self-contained and
mounted on the baseplate. The oil reservoir is built into the compressor
baseplate and coated with epoxy to resist corrosion.
The C700 uses a low pressure lubrication system to provide oil for the gears and
the hydrodynamic bearings. The design uses two oil pumps:
• a motor driven pre and post lubrication oil pump (screw type)
• a compressor shaft driven main oil pump

CENTAC lubrication system includes also:

• a suction strainer on oil line inlets Fig. 21: Demister
• check valves on the discharge line of the pre and post lubrication
oil pump and on the suction line of the main oil pump to prevent
reverse flow through the pumps
• a cast-iron adjustable relief valve to control oil pressure to the
compressor bearings
• a single element oil filter
• an oil level indicator
• a demister to condition oil vapour and to eliminate pressure build-
up in reservoir
• a brazed plate oil cooler designed for a maximum cooling water Fig. 23: Brazed plate oil cooler
temperature of 90°F
• an oil reservoir electric heater to insure adequate oil temperature for
compressor start-up
• a temperature detector mounted downstream of oil cooler for low oil
temperature and high oil temperature with analog functions on control panel
• a pressure transducer mounted downstream of oil cooler for low oil pressure
with analog function on control panel
Fig. 22: Electric heater
• SAE "dry-tech" compression fittings to avoid oil leakage from oil connections

For the schematic oil flow see also the Process & Instrumentation Diagram.

6.1 Pre and post lubrication oil pump

The pre and post lubrication oil pump lubricates the compressor bearings
and gears and fills the oil lines before the compressor starts and maintains
lubrication after the compressor has been shutdown.
It is driven by an electric motor and starts when the control panel is
energized and runs until the compressor is up to speed and the main oil
pump increases oil pressure.
The pre and post lubrication oil pump shuts down automatically when the
main oil pump is supplying the required system pressure. When the
compressor trips on the shutdown cycle, the pre and post lubrication oil
pump will start immediately and will continue to run until the panel is de-
energized, cooling down the compressor.
Fig. 24: Pre/post lube oil pump
A seal air pressure transmitter interlock prevents the pre and post
lubrication oil pump from operating if seal air pressure is not established.

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CENTAC C700

6.2 Main oil pump

The main oil pump is oversized and is driven by the main motor to
supply oil during operation and to protect the bearings during an
electrical shutdown. In the event of a main driver or power failure, the
main oil pump will continue to supply oil to the bearings and gears
during coast down. The main oil pump is mounted on the main
compressor shaft.

7 Control System
Centac compressors are equipped with a NEMA 12, 3 Phase
Fig. 25: Main oil pump
microprocessor control panel (CMC), mounted and wired on the
baseplate that provides complete integration of compressor, motor
and all auxiliary instruments. The CMC allows complete adjustment of
all electrical parameters, alarm and trip set points from the front
faceplate and can be customized to individual customer requirements.
23 analogue and 16 digital inputs and 4 analogue and 16 digital
outputs are available as standard. The CMC is fitted with multi-
language liquid crystal display providing the necessary information to
determine compressor’s operating status with Event Log of last 16
events and includes prelube oil pump motor starter, lube oil heater
contactor and control transformer.

7.1 Modulate Control Mode

Modulate maintains the system discharge pressure at the system
pressure set point as entered into the CMC by the user (±1.45 – 2.9
psi). Once loaded, the compressor will operate along the constant
pressure line until the user switches to Unload or presses the stop
button. Control is accomplished by modulating the inlet valve within
the compressor's throttle range. When system demand is less than
the minimum throttled capacity, the discharge pressure is maintained
by modulating the bypass valve and venting some of the air to Fig. 26: CMC Panel
atmosphere. This valve is opened just prior to reaching the surge line.
Whenever the bypass valve is open, the inlet valve
maintains its position at the minimum throttled capacity
setting. Modulate provides a constant discharge pressure
with variable capacity from design to zero. This control
method is used when stable control of the discharge
pressure is required. Modulate is the most commonly used
control method for Centac compressors.

7.2 Autodual Control Mode

Autodual automatically loads the machine when demand is
high and unloads the machine when demand is low. When
the compressor is controlling to pressure setpoint and
demand is within the inlet valve throttle range, constant
pressure is maintained in the same manner as Modulate.
When the machine is controlling to the pressure setpoint
and system demand is low, the compressor is operated in
the bypass valve throttle range. Autodual automatically
unloads the machine when the bypass valve is opened
beyond the Unload Point for a programmed time period Fig. 27: Modulate Control Mode
called the Unload Delay Time. The Bypass Valve Unload
Point is selected to correspond with the check valve closing

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CENTAC C700

since at this point the machine is not supplying the system. The
Unload Delay Timer should be set to prevent unloading during
short excursions through the Unload Point. The Reload Percent
determines the System Pressure at which the machine will
automatically load into the system.

8 Canopy (Option)
C700 can be provided with a sound-reducing enclosure, suitable
for indoor installation, with removable panels to allow easy
access to the inside. The enclosure is internally lined with
soundproofing material. When the canopy is provided, the
integrated inlet air filter with bypass silencer is already mounted
on the package and located on the top of the machine.

Fig. 28: Autodual Control Mode

Fig. 30: Canopy (option)

Fig. 29: Integrated inlet air filter and bypass

silencer (version with canopy option)

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